Cerlic CBX User manual

2017-12-15 C81E5EN18
CBX
Cerlic CBX
Sludge Blanket Monitor

fghj
2
CBX
Index
INDEX....................................................................................................................................................................2
1. GENERAL INFORMATION .....................................................................................................................4
SECURITY INFORMATION................................................................................................................................................. 4
DESCRIPTION OF THE FUNCTION.................................................................................................................................... 4
WORKING PRINCIPLE ....................................................................................................................................................... 4
SENSOR BODY .................................................................................................................................................................... 4
2. INSTALLATION.........................................................................................................................................5
Unpacking............................................................................................................................................................................ 5
Damages............................................................................................................................................................................... 5
Packing.................................................................................................................................................................................. 5
Content.................................................................................................................................................................................. 5
3. STARTING UP ...........................................................................................................................................5
Mechanical installation................................................................................................................................................. 6
Water connections........................................................................................................................................................... 7
Electrical connection...................................................................................................................................................... 7
Sludge rake guard limit switch, Trigger................................................................................................................ 7
USER INTERFACE .............................................................................................................................................................. 8
DESCRIPTION OF IMPORTANT DISTANCES WHEN INSTALLING CBX ........................................................................ 8
Home position, A............................................................................................................................................................... 9
Blind zone, B ....................................................................................................................................................................... 9
Max depth, C ....................................................................................................................................................................... 9
Sludge level, D .................................................................................................................................................................... 9
Measured range, E ........................................................................................................................................................... 9
Raker, F ................................................................................................................................................................................. 9
Fluff, G.................................................................................................................................................................................... 9
INSTALLATION,SOFTWARE............................................................................................................................................. 9
Configuration mode ........................................................................................................................................................ 9
Parameters.......................................................................................................................................................................... 9
Advanced settings (Defaults)....................................................................................................................................10
CBX MODE.......................................................................................................................................................................11
Rake interval ....................................................................................................................................................................11
Normal setting.................................................................................................................................................................11
Save and exit.....................................................................................................................................................................12
OPERATION ..................................................................................................................................................... 12
EMERGENCY RETRACTION OF THE CABLE...................................................................................................................12
LED INDICATION ............................................................................................................................................................ 12
BB1/BB2 MENU FOR CBX........................................................................................................................................... 13
Settings................................................................................................................................................................................13
CBX Setup...........................................................................................................................................................................14
Calibration.........................................................................................................................................................................14
Cleaning..............................................................................................................................................................................15
Scale / Alarm....................................................................................................................................................................15
System..................................................................................................................................................................................15
Timer....................................................................................................................................................................................15
INFORMATION DISPLAY ............................................................................................................................. 16
CALIBRATION ..................................................................................................................................................................16
Calibration of sensor.....................................................................................................................................................16

fghj
3
CBX
4. DETAILED INFORMATION OF CBX ................................................................................................. 17
Main control board........................................................................................................................................................17
SENSOR.............................................................................................................................................................................18
Cable drum assembly....................................................................................................................................................18
.................................................................................................................................................................................................18
Heater & fan......................................................................................................................................................................19
.................................................................................................................................................................................................19
Flushing tube & valve ...................................................................................................................................................19
Connection terminal .....................................................................................................................................................19
5. SAFETY INSTRUCTIONS, CE MARKING .............................................................................................. 20
5. MAINTENANCE...................................................................................................................................... 20
Manual operation of CBX............................................................................................................................................21
Maintenance schedule..................................................................................................................................................21
Cable and sensor.............................................................................................................................................................21
6. TROUBLESHOOTING........................................................................................................................... 22
ALARM..............................................................................................................................................................................22
COMMON SYMPTOMS AND POSSIBLE CAUSES .............................................................................................................23
TESTS................................................................................................................................................................................ 23
Quick control of the calibration...............................................................................................................................23
Control of max value.....................................................................................................................................................24
7. CONTACT INFORMATION.................................................................................................................. 24
8. WARRANTY............................................................................................................................................ 24
9. SPECIFICATION, CBX........................................................................................................................... 25
10. SPARE PARTS AND OPTIONS ...................................................................................................... 26
Spareparts P/N.........................................................................................................................................................26
Options ................................................................................................................................................................................26
11. DIMENSIONS IN MM (“).............................................................................................................. 26
APPENDIX 1, PROFILE ................................................................................................................................. 27
APPENDIX 2,SERVICE FORM..................................................................................................................... 28
APPENDIX 3, SETUP FORM........................................................................................................................ 29

fghj
4
CBX
1. General information
It is of great importance to read all parts of this manual prior to startup of the
instrument. If the Blanket Monitor is not used and handled according to this manual,
then the life and functionality may be jeopardized, and all warranties will be voided.
Security information
This instrument should be used by qualified and authorized personnel only.
It is mandatory to follow all security and other routines that apply at site when
using the CBX.
Within EU it is prohibited to dispose of electric and electronic waste in regular waste as
these may contain harmful substances. All electric and electronic waste must be
sorted and left for recycling. Such products are labeled with an X-marked waste
bin. It is important that everyone cooperate in order to secure a high level when
it comes to recycling and help to save our environment. If such waste is handled
and recycled according to regulation (EC Directive 2002/96/EC) the environment as
well as people’s health may be jeopardized.
The cable or the sensor must not be touched while it is going up or down (pinching).
CBX noise level is below 70 dB(A).
Description of the function
CBX is an optical suspended solids meter designed to measure sludge and fluff blanket
depth in clarifiers, thickeners, etc. in water and wastewater plants, as well in other
facilities. It is possible to display measured values as text or as a graphic image of the
sludge profile.
Working principle
The sensor is sent down into the clarifier/thickener and measures the suspended solids
as it descends and sends the data via a communication cable to the Control Box. By
submersing the sensor into the liquid you are able to obtain reliable suspended solids
readings versus depth and avoid problems from foam and fluff layers in the
clarifier/thickener.
Sensor body
The sensor body contains optics and electronics that should not be exposed to
mechanical abuse or high temperatures. If the sensor body has mechanical damages,
water may penetrate into the sensor and destroy the electronics and optics. Please see
section Maintenance for more information.

fghj
5
CBX
2. Installation
It is important that installation, maintenance and configuration only are done by
authorized personnel to avoid damages on the product. .
Unpacking
The unit has been tested and approved before delivery from factory. Please check to
confirm that no visible damages occurred during shipment. Make sure that all
equipment inside the cabinet is secure and that the sensor and cable can move freely.
Damages
If damages occurred during shipment, immediately contact your shipper as well as your
Cerlic representative within 2 days of receipt. The shipment may be returned only after
contact has been made with Cerlic.
Packing
The original packing is designed to protect the equipment and should be used for
storage or if the goods must be returned. If other packing material is used Cerlic is not
responsible for damages during transport.
Content
Please check that the content corresponds to your order and packing list.
3. Starting up
Connect power to the CBX and the Control Box (BB1/BB2). Connect the signal cable
between both units. The Control Box must have program version 3.1 or higher so it will
automatically detect and connect to the CBX.
It is a good idea to power CBX from the same group as the rake/stirrer
if one exists. Then both will stop at the same time at power failure or
triggered fuse. This avoids tearing the sensor off if the CBX loses
power while the rake/stirrer continues to move.

fghj
6
CBX
Mechanical installation
The support consists of two brackets, left and right hand, and a crossbar brace.
Assemble the parts according to the figure.
Hang the assembly on the handrail with the 1 ½” u-bolts or special L brackets for 4” or
6” handrails with supplied set screws. There are two leveling screws to adjust the stand
to hang horizontal/vertical.
Mount the CBX so there is no risk that the sensor will be stuck in something on the way
down in the basin. This is extra important for outdoor installations where wind can
make the sensor swing so much that it is a risk that it will stuck in,for example a hand
railing.
Make sure that the sensor runs freely, or through a detachable protection at least 50 cm
from the flushing tube. This is for reaching the sensor for control, cleaning and
calibration.
When CBX is installed outdoors there is a risk of flush lines freezing at sub zero
temperatures. This will not damage the instrument but the automatic cleaning function
will stop working. It is also recommended to use a CBX Jacket (P/N 11205969) when
there is a risk of temperatures below 23ºF (-5ºC).
Leveling screws
U-bolts for 1 ½”
handrail or 4”/6”
angled handrail.

fghj
7
CBX
Water connections
On the bottom right hand side of the cabinet there is a ¼ ” male connection for flexible
flush hose. Connect a tube with at least ½” diameter for flushing. The water pressure
shall be between 2 – 6 bar and must not exceed 6 bar (90 psi). Outdoor installations
must protect water pipe or hose from freezing conditions or the water must be
disconnected and emptied to avoid the hose or valve from freezing. Under all circum-
stances flushing should be avoided when the outdoor temperature is below 0 ºC (32ºF).
Electrical connection
In the bottom lower left corner of the cabinet there are the four ½” npt female electrical
connections. Any wires required to go outside the cabinet can be found here.
Electrical connections must be installed by authorized personnel only. The connections
are terminated in the junction box inside the cabinet on the left side.
Connection box for power supply & rake limit switch
fig 16
If emergency winding/unwinding is to be performed, use the up / down switch. NOTE!
Binding risk between cable drum and droplet drainage.
Sludge rake guard limit switch, Trigger
CBX can be installed in an environment where a moving rake is being used. This is done
by installing a border contact, closing (NO), which is controlled by the scraper’s
movement. The signal generated will be used to start the measuring cycle. It is
important that there are no objects in front of or behind the sensor when the measuring
starts.
Rake limit contact
N/O Contact 24VDC from CBX

fghj
8
CBX
The location of the border contact is crucial for achieving reliable sampling. See contact
2 and 3 (Rake limit switch) in fig 16.
All sampling modes are dependent of the connection of a rake guard limit switch which
is a N/O (normally open) contact. The digital input for the limit switch can be used in
several different ways for control of the CBX
NOTE! A limit switch must be used in all applications where a rake or other
moving equipment may come in contact with the sensor or cable. Cerlic Controls
AB does not assume any responsibility for damages caused by the absence or
malfunction of the rake guard limit switch.
Relay contact 4, 5 and 6 in fig 16. Depending on the setting on the motherboard, this
relay can be used for to indicate a fault (alarm) or ongoing measurement.
User interface
The Control Box (BB1/BB2) will show the CBX as a standard “X” sensor on the display
and it will show both sludge and fluff level in text on the display. If only one sensor
location is used on the Control Box, CBX will display the previous sludge level,
concentration and depth in real time during soldering. All configuration is done via the
Control Box to which CBX is connected.
Description of important distances when installing CBX
The figure below shows the different terms used for distances that are involved in the
configuring of the CBX.

fghj
9
CBX
Home position, A
The sensor will always return to this position.
Blind zone, B
Sludge or foam detected in this zone during lowering of the sensor is not registered.
Unwanted interference is prevented by setting this zone to be 1’ (0.3m) below the
normal liquid surface. Sensor does not start to measure until it reaches this distance.
Max depth, C
This is the maximum distance from the home position. The sensor will stop at this depth
if no sludge is detected. The sensor might stop and return at a shorter distance if a rake
guard offset is entered (F).
Sludge level, D
The sludge level distance from bottom found when the preset sludge concentration is
reached.
Measured range, E
The output signal will vary from 4-20 mA within this range.
Raker, F
This denotes the safe height from the bottom (Max depth) to a point where the sensor
always must stop and then turn back to home position to alleviate hitting the bottom
rake.
Fluff, G
The fluff layer or depth found when the present fluff concentration is reached.
Installation, software
Turn on power to the device.
Configuration mode
Set the CBX in configuration mode, using the control panel:
Menu path
CBX → Calibrate → Mod → Conf
i
The green LED on the door should now blink. This indicates that it is in configuration mode.
In this mode no automatic measurements will take place, only manual control is allowed.
The Trig signal is ignored, this means also that the operator is responsible for having the
cable stretched and that a safe measurement can take place (no rake nearby).
Parameters
The following procedure sets the different depths and controls the calibration. This must
not be done without controlling if the sensor can move freely into the basin with regard to
scrapers, rakes, stirrers or such.
Go to calibration menu and chose manual operation and press down. The sensor will
now start to lower itself towards the liquid surface. Stop when it is a few centimeters
below the surface.
Note the depth on the display. This gives the value for ”Blind zone”.
Keep an eye on the measurement (sludge). It should now be relatively low being in the
clear phase.

fghj
10
CBX
On the way down, observe the variation of the sludge value with the depth. Often two
rather sudden leaps can be observed, first when the clear phase goes to fluff and then
when fluff merges to sludge.
Check to see if there is a suitable value for fluff and sludge.
Example:
The sensor measures about 500 mg/l in clear phase, 1500 mg/l in fluff-area, and 10000
mg/l in sludge.
Appropriate thresholds are 1000 mg/l for fluff, and 6000 mg/l for sludge.
Memorize or note these leap values.
Be observant when the sensor starts to reach the bottom. If the basin is equipped with
scrapers on chains, you will have to find out the max depth from the drawings of the
basin, then the CBX will make an automatic adjustment to the height of the scrapers,
after a correct ”Rake Height” has been noted.
If there is clear ground between the scrapers, then the following procedure can be used:
When the sensor is touching the bottom the cable will go slack. Stop immediately and
feed the sensor back up until the sensor hangs freely and the cable is stretched. Note the
distance on the BB1/BB2, this is the Max Depth (C). Feed sensor all the way back up.
Advanced settings (Defaults)
Now fill in the values that you recorded at the test above.
Menu path
CBX → Set up → Avanc.CBX → Max depth
The value for this shall be the deepest value in the basin, which can be calculated from
the construction drawing.
Menu path
CBX → Set up → Avanc.CBX → Blindzone
This shall be the value down to several inches below the surface. This will prevent the
sensor from measuring in the air or surface sludge.
Menu path
CBX → Set up → Avanc.CBX → Rake height
If there are scrapers, then note the height on these here, to prevent the sensor from
reaching them.
If not, leave the value at 0.
Menu path
CBX → Set up → Avanc.CBX → Trig
This set up is for how many trig-signals pass before a measurement starts. If the value is
1,a measurement will be done at every trig-signal. At 2, every other . Normally the trig-
signal is connected to the scrape, and after it passes a measurement will be done, for
example every 5th time or suitable interval depending on the speed of the scrape. This
value must not be 0 (other than a method to shut off the measurement in an empty
basin) as no measurement will be taken.
Verify remaining set-ups in this menu:
Menu path
CBX → Set up → Avanc.CBX → Mains frek
Main frequency. 50 or 60 Hz.
Menu path
CBX → Set up → Avanc.CBX → Rake int.
Delay after trig. With this the measurement can be delayed a number of desired seconds
after the trig signal. This can be very useable if you want to extend the distance after the
passage of the scrape until the measuring point.
Menu path
CBX → Set up → Avanc.CBX → Track
Level: Normal location. CBX measures until known sludge threshold is found, and then
returns to box.
Profile: In this mode the sensor measures the depth of the whole basin to enable to
superior system which can draw a sludge profile. This demands a rather advanced
preparation in superior system and central unit, see app. 1.